Modular heat pump system

ABSTRACT

An HVAC system utilizes one or more modular heat pump units installed within an outer wall or corner of a building, and one or more active registers. A central hub, which can be integrated into a modular HVAC unit, receives input from thermostats and sensors in the building and adjusts operation of the modular HVAC units and active registers to distribute conditioned air throughout the building. The system provides convenience and comfort of a traditional split HVAC system with significantly reduced installation and maintenance costs. The modular HVAC unit includes an interchangeable cartridge that contains the active components of a heat pump. Cartridges of different capacities can be installed as required, and are easily swapped out for maintenance, servicing, and replacement. A user can control the system using traditional-style thermostats and with a smart phone, tablet or computer. A cloud server provides backup services and remote access to the system.

BACKGROUND 1. Technical Field

The present disclosure relates generally to heating, ventilation, andair conditioning (HVAC) systems, and in particular, to a modularpackaged heat pump system that requires no special HVAC skills orcertifications to install.

2. Background of Related Art

Installing an HVAC system can be complicated, time-consuming andexpensive in new construction, and even more so in an old constructionretro-fit. The system components must be carefully selected to deliverthe required heating and cooling capacity. Air delivery and returnductwork must be planned and installed throughout the building.Depending on building architecture, this can be a challenging task andrequire encroachments into living and storage space in the form ofdropped ceilings, boxed-in soffits, reduced closet space, reduced atticspace, and so forth. Refrigerant lines must be run between the outdoorunit (which includes a compressor, fan, and outdoor heat exchanger coil)and the indoor unit (which includes a blower and indoor heat exchangercoil). A certified technician is required to purge, evacuate, and chargethe system with refrigerant in accordance with strict technical andregulatory standards. Multiple electrical and control wiring runs areneeded to connect HVAC components to power and to each other. In thecase of buildings that use multiple HVAC zones, the entire installationprocess is repeated two, three, or more times.

This approach can have drawbacks. The availability of skilled andcertified HVAC technicians is often in short supply, leading toconstruction delays and increased installation costs. Improper HVACsizing and ductwork design can lead to overly hot or cold rooms. Repairand replacement of the outdoor unit or indoor unit can be inconvenientand costly. Once the system is fully installed, there is little or noflexibility to revise the system without incurring substantial cost andinconvenience.

An HVAC system that addresses these shortcomings would be a welcomeadvance in the art.

SUMMARY

In one aspect, the present disclosure is directed to an in-wallenclosure for mounting a modular HVAC cartridge. The in-wall enclosureis dimensioned to fit within a space between an exterior sheathing of abuilding, a first vertical wall stud, and a second vertical wall stud.The enclosure includes an indoor duct opening and an outdoor ductopening, an outdoor air inlet, and a front opening that exposes a cavitywhich can receive a modular HVAC cartridge. An indoor duct may extendfrom the indoor duct opening to an indoor duct outlet. Additionally oralternatively to the indoor duct, an outdoor duct may from the outdoorduct opening to an outdoor duct outlet. In some embodiments, theenclosure includes an outlet port through which condensate, e.g., watergenerated from the dehumidification of air, is expelled. The in-wallenclosure may include an electrical connector disposed in the cavity.The electrical connector may be designed to electrically engage a matingconnector provided on a modular HVAC cartridge when the modular HVACcartridge is positioned in the in-wall enclosure.

In another aspect, the present disclosure is directed to a modular HVACcartridge. The cartridge includes a housing having at least a rear side,a top side, and a front side. The cartridge housing is sized to matewith the cavity of the in-wall enclosure described above. The cartridgeincludes an indoor air port that is configured to mate with the indoorduct of the in-wall enclosure. Additionally or alternatively, thecartridge includes an outdoor air port that is configured to mate withthe outdoor duct of the in-wall enclosure. The cartridge includes anindoor air inlet and an outdoor air inlet. An indoor coil is disposedbetween the indoor air inlet and the indoor air port and an outdoor coildisposed between the outdoor air inlet and the outdoor air port. Thecartridge includes an indoor fan for moving indoor air from the indoorair inlet to the indoor air port and an outdoor fan for moving outdoorair from the outdoor air inlet to the outdoor air port. A refrigerantcompressor is in fluid communication with the indoor coil and theoutdoor coil to perform a vapor-compression refrigeration cycle. Thecartridge may include a reversing valve to enable cooling (airconditioning) or heating (heat pump) operation.

In some embodiments, the HVAC cartridge includes an indoor condensatepan positioned beneath the indoor coil and/or an outdoor condensate panpositioned beneath the outdoor coil. A drain pipe having an upper endand a lower end may be included, wherein the upper end is in fluidcommunication with the indoor condensate pan, and wherein the lower endis in fluid communication with the outdoor condensate pan, to enablefluid to drain from the upper pan into the lower pan.

In some embodiments, the HVAC cartridge includes a control module. Thecontrol module includes a communications interface and controller unithaving a processor and a memory. The memory stores instructionsexecutable by the processor which, when executed by the processor, causethe processor to adjust the operation of the indoor fan, the outdoorfan, and/or the compressor. In some embodiments, the memory furtherincludes instructions executable by the processor which, when executedby the processor, cause the processor to receive, from thecommunications interface, an operational parameter of the modular HVACcartridge and/or to transmit, to the communications interface, anoperational status of the HVAC cartridge. The HVAC cartridge may includea peripheral dock having a data interface compatible with a deviceselected from the group consisting of a CO₂ sensor, a video camera, asmart phone, a lighting controller, room lights, an audio playbackdevice, and a flat panel interface. The peripheral dock may include anelectrical power connector to power the peripheral device. In someembodiments, the indoor coil is divided into two sections that may beselectively coupled in a parallel configuration to facilitate a heatingor cooling mode, or in a serial configuration to facilitate adehumidification mode.

In yet another aspect, the present disclosure is directed to a modularHVAC system. The system includes a modular HVAC cartridge, a control hubin operative communication with the modular HVAC cartridge, atemperature sensor in operative communication with the control hub, anactive register in operative communication with the control hub, and amobile device in operative communication with the control hub. Inembodiments, the mobile device includes a processor and a memoryincluding instructions executable by the processor which, when executedby the processor, cause the mobile device to transmit a temperaturesetpoint to the control hub and/or to receive an operational status fromthe control hub. In embodiments, the control hub comprises a processorand a memory including instructions executable by the processor which,when executed by the processor, cause the control hub to receive atemperature setpoint from the mobile device; receive a temperaturemeasurement from the temperature sensor; and transmit an operationalparameter to the active register based on the temperature setpoint andthe temperature measurement.

In some embodiments, the control hub includes a processor and a memoryincluding instructions executable by the processor which, when executedby the processor, cause the control hub to receive a temperaturesetpoint from the mobile device; receive a temperature measurement fromthe temperature sensor; and transmit an operational parameter to themodular HVAC cartridge based on the temperature setpoint and thetemperature measurement. In some embodiments, the modular HVAC systemincludes a thermostat that communicates with the control hub. The memoryof the may including instructions executable by the processor which,when executed by the processor, cause the control hub to receive atemperature setpoint and/or an operational parameter from thethermostat; and transmit an operational parameter to the modular HVACcartridge based on the temperature setpoint and/or the operationalparameter.

In some embodiments, the modular HVAC system includes a remote server inoperative communication with the control hub. The remote server includesa processor and a memory programmed with instructions to cause theremote server to receive one or more operational parameters from thecontrol hub; store the received operational parameters in a backupdatabase; and transmit one or more of the stored operational parametersto the control hub. The remote server may be programmed to receive oneor more operational parameters from the mobile device; and transmit oneor more of the received operational parameters to the control hub.

The active register includes a communications interface, at least onefan, and a controller. The active register controller includes aprocessor, and a memory programmed with instructions to cause the activeregister to receive a fan command from the control hub; and adjust thespeed of the fan in accordance with the fan command. The active registermay additionally or alternatively be programmed to receive a setpointtemperature from the control hub; receive a temperature measurement fromthe temperature sensor; and adjust the fan speed in accordance with thesetpoint temperature and the temperature measurement. In someembodiments, the active register may additionally or alternatively beprogrammed to transmit the fan speed to the control hub.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments of the disclosed invention are described hereinwith reference to the drawings wherein:

FIG. 1 is a perspective view of an exemplary embodiment of a modularHVAC unit viewed from the indoor side;

FIG. 2 is a perspective view of an exemplary embodiment of a modularHVAC unit viewed from the outdoor side;

FIG. 3 is an upward-facing view of the underside of a top surface of anin-wall enclosure according to an exemplary embodiment of the presentdisclosure;

FIG. 4A is a perspective view of an exemplary embodiment of a modularHVAC unit with the cartridge unit removed as viewed from the indoorside;

FIG. 4B is a view of exemplary embodiment of a modular HVAC unit withthe cartridge unit removed mounted between two wall studs;

FIG. 5 is a cutaway view of an exemplary embodiment of an HVAC cartridgeunit in accordance with the present disclosure viewed from the indoorside;

FIG. 6 is a cutaway view of an exemplary embodiment of an HVAC cartridgeunit in accordance with the present disclosure viewed from the outdoorside;

FIG. 7 is a view of an HVAC cartridge unit just prior to installationinto a modular HVAC enclosure;

FIG. 8 is a view of a cartridge unit installed into a modular HVAC unit;

FIG. 9 is a pictorial diagram of a modular HVAC system in accordancewith an exemplary embodiment of the present disclosure;

FIG. 10 is a block diagram of a modular HVAC system in accordance withan exemplary embodiment of the present disclosure; and

FIGS. 11A-D are views of an exemplary embodiment of a modular HVAC unitin accordance with the present disclosure that is configured forinstallation in a corner of a room.

Aspects of the present disclosure mentioned above are described infurther detail with reference to the aforementioned figures and thefollowing detailed description of exemplary embodiments.

DETAILED DESCRIPTION

Particular illustrative embodiments of the present disclosure aredescribed hereinbelow with reference to the accompanying drawings,however, the disclosed embodiments are merely examples of thedisclosure, which may be embodied in various forms. Well-known functionsor constructions, such as the fundamental operation of a vaporcompression heat pump system, as well as repetitive matter, are notdescribed in detail to avoid obscuring the present disclosure inunnecessary or redundant detail. Therefore, specific structural andfunctional details disclosed herein are not to be interpreted aslimiting, but as a basis for the claims and examples for teaching oneskilled in the art to variously employ the present disclosure in anyappropriately-detailed structure. In this description, as well as in thedrawings, like-referenced numbers represent elements which may performthe same, similar, or equivalent functions. The word “exemplary” is usedherein to mean “serving as a non-limiting example, instance, orillustration.” Any embodiment described herein as “exemplary” is notnecessarily to be construed as preferred or advantageous over otherembodiments. The word “example” may be used interchangeably with theterm “exemplary.”

Aspects of the present disclosure may be described herein in terms offunctional block components and various processing steps. It should beappreciated that such functional blocks configured to perform thespecified functions may be embodied in mechanical devices,electromechanical devices, analog circuitry, digital circuitry, and/ormodules embodied in a computer. For example, the present disclosure mayemploy various discrete components, integrated circuit components (e.g.,memory elements, processing elements such as microprocessors ormicrocontrollers, logic elements, look-up tables, and the like) whichmay carry out a variety of functions, whether independently, incooperation with one or more other components, and/or under the controlof one or more processors or other control devices. The expressdisclosure of a component (e.g., processor, memory, driver, interface,etc.) used in one element should not be construed to exclude the use ofa similar component that may not be expressly disclosed in anotherelement. One skilled in the art will also appreciate that, for securityreasons, any element of the present disclosure may includes any ofvarious suitable security features, such as firewalls, access codes,passwords, authentication, encryption, de-encryption, compression,decompression, and/or the like. It should be understood that the stepsrecited herein may be executed in any order and are not limited to theorder presented. Moreover, two or more steps or actions recited hereinmay be performed concurrently.

FIGS. 1-2 illustrate a modular HVAC unit 100 in accordance with anexemplary embodiment of the present disclosure. HVAC unit 100 ispreferably dimensioned to fit within an exterior wall of a building, andincludes an indoor side 125 as seen in FIG. 1 and an outdoor side 126 asseen in FIG. 2. In an embodiment, HVAC unit 100 has an overall size ofabout 14.5 inches wide, 5.5 inches deep, and about 7 feet high to enableHVAC unit 100 to fit neatly between two studs, the exterior wall orsheathing, and the interior wall (e.g., drywall) of a typical building,such as a residential home. HVAC unit 100 includes an in-wall enclosure105 that is configured to operatively receive a replaceablerefrigeration cartridge unit 110. As seen in FIG. 3, in-wall enclosure105 includes a top surface 103 having an indoor duct opening 101 and anoutdoor duct opening 102 defined therein, to which an indoor duct 115and an outdoor duct 120 are respectively attached. The outdoor side 126includes an outdoor inlet louver 112 to allow outside air to be drawninto enclosure 105. A condensate outlet port 113 enables condensate todrain from HVAC unit 100 to the outdoor environment. An upper end ofindoor duct 115 includes an indoor outlet louver 116 configured todirect conditioned air into the interior of the building. An upper endof outdoor duct 120 includes an outdoor outlet louver 121 configured toexhaust air from in-wall enclosure 105 to the outdoor environment. FIG.4A illustrates modular HVAC unit 100 with cartridge unit 110 removed. Anelectrical connector 129 is provided by in-wall enclosure 105 to supplyelectrical power to cartridge unit 110. FIG. 4B illustrates modular HVACunit 110 with cartridge unit 110 removed installed between wall studs Sof a residential building, e.g., one under construction. Advantageously,in a retro-fit application, the modular HVAC unit 100 may installed withminimal disruption to the building structure, typically less than onesheet of drywall is disturbed.

With reference now to the exemplary embodiment shown in FIGS. 5 and 6,refrigeration cartridge unit 110 is a self-contained heat pump packagedin cartridge unit housing 104 that is selectively installable intoin-wall enclosure 105. Cartridge unit 110 includes components typicallyfound in both an outdoor unit and indoor unit of a split heat pumpsystem to provide an integrated, “plug and play” HVAC installation.

An outdoor section 132 of cartridge unit 110 includes compressor 106 andan outdoor fan 109 that draws in outdoor air through an outdoor inletfilter 128 disposed on a lower portion of outdoor side 126. Outdoor fan109 may be driven by a fixed-speed or a variable-speed motor 134. Insome embodiments, outdoor fan 109 is a centrifugal blower. Outdoor inletfilter 128 is positioned to be in substantial alignment with outdoorinlet louver 112 when cartridge unit 110 is installed into in-wallenclosure 105, and aids in preventing debris and pests from enteringHVAC unit 100. Outdoor coil 107 is positioned between outdoor inletfilter 128 and the intake of outdoor fan 109. The exhaust of outdoor fan109 is coupled to outdoor fan exhaust duct 124 that terminates at anoutdoor air port 127. Outdoor air port 127 is configured to be insubstantial alignment with outdoor duct opening 102 of in-wall enclosure105 when cartridge unit 110 is installed into in-wall enclosure 105,therefore enabling air to flow from cartridge unit 110 upwards throughoutdoor duct 120 to the outdoor environment via outdoor outlet louver121. An outdoor condensate pan 122 is positioned beneath outdoor coil107 to collect condensate (e.g., water) that may precipitate fromoutdoor coil 107. Condensate pan 122 is pitched to permit collectedcondensate to drain from condensate pan 122 to the outdoors viacondensate outlet 113.

Cartridge unit 110 includes an indoor section 131 having an indoor inletlouver 111, an indoor inlet filter 133, an indoor coil 117, an indoorcondensate pan 118, and one or more indoor fans 108. Indoor inlet filter133 aids in preventing dust and allergens from entering HVAC unit 100.In embodiments, indoor inlet filter 133 may include a HEPA filter, anelectrostatic filter, and/or an air purifier that utilizes ultravioletlight to disinfect indoor air. The one or more indoor fans 108 may bedriven by fixed-speed or variable-speed motors, and may be operated intandem, or individually (e.g., in a staged configuration). Indoor airport 130 is configured to be in substantial alignment with indoor ductopening 101 of in-wall enclosure 105 when cartridge unit 110 isinstalled into in-wall enclosure 105, therefore enabling conditioned airto flow from cartridge unit 110 upwards through indoor duct 115 and intothe conditioned space via indoor outlet louver 116. Indoor condensatepan 118 is positioned beneath indoor coil 117 to collect condensate(e.g., water) that may precipitate from indoor coil 117. Indoorcondensate pan 118 is pitched to enable condensate to drain into a drainpipe 119 that empties into outdoor condensate pan 122, and from outdoorcondensate pan 122 to the outdoors via condensate outlet 113 asdescribed above.

Cartridge unit 110 includes control module 114 that adjusts theoperation of indoor fan(s) 108, outdoor fan 109 and compressor 106 asdescribed herein. In some embodiments, indoor coil 117 is divided intotwo sections that may be selectively coupled in a parallel or serialconfiguration, which enables heat pump 100 to provide a heating orcooling mode while in a parallel configuration, and a dehumidificationmode while in a serial configuration. A heat pump that provides heating,cooling, and/or dehumidification modes is disclosed in U.S. patentapplication Ser. No. 15/485,439, filed Apr. 12, 2017, entitled“MULTI-FUNCTIONAL HEAT PUMP APPARATUS” which is assigned to the assigneeof the present application and is hereby incorporated by referenceherein for all purposes.

During use, the one or more indoor fans 108 draw indoor air throughindoor inlet louver 111 and indoor inlet filter 133, through indoor coil117 to cool the indoor air in cooling mode or to heat indoor air inheating mode, and out through indoor air port 130. Concurrently, outdoorair is drawn in by outdoor fan 109 though outdoor inlet louver 112 andoutdoor inlet filter 128, passes through outdoor coil 107 to exchangeheat between indoor coil 107 and the outdoor air, and exhausts thoughexhaust duct 127 and outdoor duct 120. In some embodiments, cartridgeunit 110 includes a ventilation damper (not explicitly shown) thatenables fresh outdoor air to be drawn into the indoor space and/or staleindoor air to be exhausted to the outdoors. In some embodiments,cartridge unit 110 includes a heat recovery ventilator (HRV) or anenergy recovery ventilator (ERV) (not explicitly shown) to provideventilation while limiting thermal losses and/or undesirable humiditychanges in the indoor space.

FIG. 7 illustrates a cartridge unit 110 as it is inserted into aninstalled in-wall enclosure 105. Electrical power is provided tocartridge unit 110 by electrical connector 129 provided by in-wallenclosure 105. In some embodiments, electrical connector 129 can be astandard 120 VAC or 240 VAC outlet into which a pigtail line cord (notexplicitly shown) from cartridge unit 110 is plugged. In someembodiments, electrical connector 129 can include a quick-connectmechanism that engages with a mating connector provided on cartridgeunit 110 as cartridge unit 110 is positioned into in-wall enclosure 105.Cartridge unit 110 includes a handle 135 on either side to allowcartridge unit 110 to be moved about in a safe and convenient manner. Agasket 123 effectuates a seal between outdoor air port 127 and indoorair port 130 with corresponding outdoor duct opening 102 and indoor ductopening 101, respectively. Advantageously, cartridge unit 110 may bereadily removed for maintenance, service, to swap out an existingcartridge unit 110 for another cartridge unit 110 having a differentheating/cooling capacity, and/or to upgrade to a cartridge unit 110having newer features, for example.

When fully inserted into in-wall enclosure 105, cartridge unit 110 liessubstantially flush with the adjacent wall (FIG. 8). As will beappreciated, indoor duct 115 and outdoor duct 120 are hidden behind theinterior wall, with only the indoor outlet louver 116 and the indoorside 125 of cartridge unit 110 remaining visible. Indoor side 125 ofcartridge unit 110 may be formed from a readily paintable material, suchas a primer coat, and/or may include clips or a similar mechanism toenable cartridge unit 110 to accept a finish similar or identical to theroom in which it is installed, e.g., house paint, wallpaper, paneling,wainscoting, and so forth.

FIGS. 9-10 illustrate an embodiment of a modular HVAC system 150 inaccordance with an exemplary embodiment of the present disclosure.Modular HVAC system 150 includes at least one modular HVAC unit 110installed in an outer wall of a home, and a control hub 160 thatcoordinates the operation of each component of HVAC system 150 asdescribed herein. In some embodiments, control hub 160 may be includedwithin controller 114 of modular HVAC unit 110. In embodiments having aplurality of modular HVAC units, one such control hub 160 includedwithin controller 114 is designated as a primary controller, while theother controllers 160 may be designated as a failover controller. A roomin which a modular HVAC unit 110 is installed is referred to herein as aprimary room. A room in which no modular HVAC unit 110 is installed isreferred to herein as a secondary room.

A mobile device 138 in operative communication with control hub 160 maybe used by a user to adjust the operational parameters of modular HVACsystem 150. Non-limiting examples of operational parameters includesystem on/off, temperature setpoint, humidity setpoint, scheduling,indoor fan speed, outdoor fan speed, compressor speed, ventilationdamper position, operational mode, and so forth. Operational mode caninclude heating mode, cooling mode, dehumidification mode, ventilationmode, and/or an automatic mode whereby operational mode is determinedfrom indoor conditions, outdoor conditions, weather forecast data,time-of-day, and/or time-of-year (seasonal) data. In an embodiment,mobile device 138 can be a smart phone, tablet computer, notebookcomputer and/or a desktop computer. User device 380 includes applicationsoftware 144 that facilitates interaction between the user and controlhub 160.

HVAC system 150 includes a thermostat 136 positioned within the home.Thermostat 136 includes a communications interface 157, a sensor 147configured to measure an environmental parameter within the home such astemperature and/or humidity, and a user interface 148 that facilitatesuser interaction between the user and thermostat 136 to enable the userto adjust operational parameters of modular HVAC system 150 as describedabove. Communications interface 157 is configured for operativecommunication with control hub 160 to enable thermostat 136 to exchangeoperational parameters and system status with modular HVAC system 150.In embodiments where HVAC system 150 includes a plurality of modularHVAC units 110, an equal number of thermostats 136 may be provided. Inthese embodiments, each thermostat 136 may be paired with acorresponding modular HVAC unit 110.

HVAC system 150 includes at least one room sensor 137 positioned withinthe home. Room sensor 137 includes a communications interface 155, and asensor element 156 configured to measure an environmental parameterwithin the home such as temperature and/or humidity. Sensor 156 sensesan environmental condition in the vicinity of room sensor 137, e.g.,temperature and/or humidity, and communicated via HVAC network 139 to,for example, control hub 160 and/or modular HVAC unit 110 bycommunications interface 155. A room sensor 137 may be installed in asecondary room to enable modular control hub 160 to determine whetherconditioned air is being effectively distributed throughout the home.

Control hub 160 is in operative communication with at least one activeregister 140 which circulates conditioned air between rooms to achieveconsistent environmental conditions throughout the home. Active register140 is configured for mounting though an interior wall of the home andincludes a controller 151, a communications interface 152, anenvironmental sensor 154 and at least one fan 153 that selectively movesair between the interior spaces or room separated by the wall throughwhich active register 140 is mounted. In embodiments, active register140 can selectively move air in either direction, which may be achievedby, for example, reversing the direction of rotation of fan 153, throughthe use of variable pitch fan blades, and/or the use of separate fans153 for each direction of airflow.

Active register 140 may be associated with a modular HVAC unit 100installed in a primary room and a room sensor 137 positioned within asecondary room. During use, the associated room sensor 137 communicatesthe environmental conditions within the secondary room served by activeregister 140 to control hub 160. Control hub 160 compares theenvironmental conditions within the secondary room to the setpoint ofthe associated modular HVAC unit 100 (e.g., the setpoints for theprimary room) to determine whether an imbalance exists (e.g., thesecondary room is too hot or too cold compared to the primary room).Control hub 160 then causes active register 140 activate fan 153 to moveair in the appropriate direction to balance the environmental conditionwithin the secondary room toward the setpoint.

In an embodiment, active register 140 may operate in a semi-autonomousmode whereby an associated room sensor 137 communicates environmentalconditions of the secondary room to active register 140. Anenvironmental sensor 149 included in active register 140 senses theenvironmental conditions of the primary room. Controller 151 comparesthe environmental conditions of the primary room to the environmentalconditions of the secondary room and activates fan 153 to move air inthe appropriate direction to adjust the environmental condition withinthe secondary room toward the environmental conditions of the primaryroom, or vice versa.

With continued reference to FIG. 9, the various components of modularHVAC system 150 (e.g., modular HVAC unit 110, active register 140, roomsensor 137, thermostat 136, user device 138, control hub 160) include acommunications interface configured to enable said modules tocommunicate between and among themselves via HVAC network 139. In anexemplary embodiment, HVAC network 139 is a wireless network thatoperates in accordance the IEEE 802.11 set of standards known as “WiFi.”Additionally or alternatively, HVAC network 139 operates in accordancewith the IEEE 802.15.4 set of wireless communications standards andextensions thereof, such as without limitation Z-Wave®, Zigbee®, and/orBluetooth®. In some embodiments, HVAC network 139 additionally operatesin accordance with one or more wired communications standards such as,without, limitation, Ethernet, RS-485, and so forth.

Module 114 of modular HVAC unit 110 includes a controller 158 and acommunications interface 159. Controller 158 is in operativecommunication with compressor 106, indoor fan 108, outdoor fan 109,reversing valve 142, and ventilation damper 143 to adjust the operationthereof. Controller 158 is in operative communication with indoor sensor145 and outdoor sensor 146 to sense an environmental condition, e.g.,temperature and/or humidity, in the interior conditioned space and/oroutdoor environment, respectively.

Active register 140 includes a controller 151, and a communicationsinterface 152. Communications interface 152 receives fan controlcommands from, for example, control hub 160, which are communicated tocontroller 151. Controller 151 is in operative communication withcommunications interface 152 and fan 153 to adjust the speed and/ordirection of fan 153, and with sensor 154 to sense an environmentalcondition in the vicinity of active register, e.g., temperature and/orhumidity.

Thermostat 136 includes a communications interface 155, a user interface148, and a sensor 147. User interface 148 enables a user to entersettings, such as temperature setpoint, operating mode, schedule, and soforth, and communicates the user settings via HVAC network 139 tocontrol hub 160 and/or modular HVAC unit 110. Thermostat 136 may receivestatus, operational, informational, and diagnostic information viacommunications interface 157 which may be displayed on user interface148. Thermostat 136 includes an environmental sensor 147 configured tosense an environmental condition in the vicinity of thermostat 136,e.g., temperature and/or humidity. As will be appreciated by one ofordinary skill, thermostat 136 compares the sensed environmentalcondition, such as temperature, to a setpoint, and communicates a signalto modular HVAC unit 110, control hub 160, or other suitable device toactivate or deactivate modular HVAC unit 110 to maintain the conditionedspace at the desired setpoint. Thermostat 136 may additionally oralternatively communicate the sensed environmental parameter to modularHVAC unit 110, control hub 160, or other device in modular HVAC system150. A software application 144 (“app”) executing on a user's userdevice 138 enables a user to interact with modular HVAC system 150 toset system operating parameters and to obtain system status.

Modular HVAC system 150 communicates with remote server cloud 141 thatis accessible via the public internet 164. A user can establish a useraccount at remote server cloud 141 and associate the account withmodular HVAC system 150. A user account may be established and accessedby a website portal provided by remote cloud server 141 and/or usingsoftware application 144. Modular HVAC system 150 communicates usersetting and system status to remote server cloud 141 for backup and toact as a gateway between user device 138 and HVAC network when userdevice 138 is outside the range of HVAC network 139. In this scenario,user device 138 communicates with remote server cloud 141 via the publicinternet 164 using cellular or local WiFi services. Remote server cloud141, in turn, relays user settings and status information betweenmodular HVAC system 150 and user device 138. In some embodiments, a usermay enter settings and/or receive status information using a web portalprovided by remote server cloud 141.

FIGS. 11A-D illustrate a modular HVAC unit 200 in accordance withanother exemplary embodiment of the present disclosure. In contrast tomodular HVAC unit 100 that is installed into a wall of a building,modular HVAC unit 200 is installed in a corner location of a room, suchthat HVAC unit 200 fits neatly within the corner framing “F” of thebuilding. Modular HVAC unit 200 includes an in-wall enclosure 205 thatis configured to operatively receive a replaceable refrigerationcartridge unit 210. In-wall enclosure 205 includes an indoor duct 215and an outdoor duct 220. A compressor 206 circulates refrigerant throughoutdoor coil 207 and indoor coil 217 to effectuate a vapor-compressionrefrigeration cycle. An outdoor inlet louver 212 is configured to allowoutside air to be drawn into enclosure 205 by outdoor fan 209, andthrough outdoor coil 207 to exchange heat between the outdoor air andoutdoor coil 207. As will be appreciated by the skilled artisan, incooling mode, heat is moved out of outdoor coil 207 to the outdoor airflowing therethough, while in heating mode, heat is moved from outdoorair into outdoor coil 207. Outdoor air continues upwards through outdoorduct 220, and exhausted through outdoor outlet louver 221. Outdoor fan209 may be driven by a fixed-speed or a variable-speed motor 234. Insome embodiments, outdoor fan 209 is a centrifugal blower.

An indoor fan 208 draws indoor air through indoor inlet louver 211,which passes through indoor coil 217, through indoor fan 208, up throughindoor duct 215, and directed into the indoor conditioned space thoughindoor outlet duct 216.

An indoor condensate pan 218 is positioned beneath indoor coil 217 andan outdoor condensate pan 222 is positioned under outdoor coil 207.Condensate that is collected in indoor condensate pan 218 flows throughdrain pipe 219 to outdoor condensate pan 222. Condensate collected inoutdoor condensate pan 222 drains to the outdoors through condensateoutlet 213.

Modular HVAC unit 200 includes control module 214 that adjusts theoperation of indoor fan(s) 208, outdoor fan 209 and compressor 206 asdescribed herein. Modular HVAC unit 200 includes a peripheral dock 235that enables a smart home appliance to be connected to modular HVAC unit200. Examples of a smart home appliance include a CO₂ sensor, asurveillance or baby monitor camera, room lights, an audio playbackdevice that can includes a speaker, a flat panel interface for a smarthome control system, and other small appliances. A smart appliance maybe connected to modular HVAC unit 200 via a physical electricalconnection and/or by a wireless connection. A charging connection, suchas a powered USB port, may be provided in some embodiments. A connectedsmart appliance can be added to the controlled or managed through useraccount at remote server cloud 141 and/or software application 144, andmay be manually or automatically associated with modular HVAC unit 200

Aspects

It is noted that any of aspects 1-23 may be combined with each other inany suitable combination.

Aspect 1. An in-wall enclosure for mounting a modular HVAC cartridgewithin a space defined by an exterior sheathing of a building, a firstvertical stud, and a second vertical stud, comprising an indoor ductopening and an outdoor duct opening defined therein; an outdoor airinlet defined therein; and a front opening exposing a cavity configuredto operatively receive a modular HVAC cartridge.

Aspect 2. The in-wall enclosure in accordance with aspect 1, furthercomprising an indoor duct extending from the indoor duct opening to anindoor duct outlet; and an outdoor duct extending from the outdoor ductopening to an outdoor duct outlet.

Aspect 3. The in-wall enclosure in accordance with aspect 1 or 2,further comprising a condensate outlet port.

Aspect 4. The in-wall enclosure in accordance with any of aspects 1-3,further comprising an electrical connector disposed in the cavity.

Aspect 5. The in-wall enclosure in accordance with any of aspects 1-4,wherein the electrical connector is positioned to electrically engage amating connector provided on the modular HVAC cartridge when the modularHVAC cartridge is positioned in the in-wall enclosure.

Aspect 6. A modular HVAC cartridge, comprising a housing having at leasta rear side, a top side, and a front side, the housing dimensioned tomate with the cavity of an in-wall enclosure; an indoor air port definedin the housing and configured to mate with the indoor duct of an in-wallenclosure; an outdoor air port defined in the housing and configured tomate with the outdoor duct of an in-wall enclosure; an indoor air inletdefined in the housing; an outdoor air inlet defined in the housing; anindoor coil disposed between the indoor air inlet and the indoor airport; an indoor fan for moving indoor air from the indoor air inlet tothe indoor air port; an outdoor coil disposed between the outdoor airinlet and the outdoor air port; an outdoor fan for moving outdoor airfrom the outdoor air inlet to the outdoor air port; and a compressor influid communication with the indoor coil and the outdoor coil forperforming a vapor-compression cycle.

Aspect 7. The modular HVAC cartridge in accordance with aspect 6,wherein the modular HVAC cartridge further comprises an indoorcondensate pan positioned beneath the indoor coil; and an outdoorcondensate pan positioned beneath the outdoor coil.

Aspect 8. The modular HVAC cartridge in accordance with aspect 6 or 7,further comprising a drain pipe having an upper end and a lower end,wherein the upper end is in fluid communication with the indoorcondensate pan, and wherein the lower end is in fluid communication withthe outdoor condensate pan.

Aspect 9. The modular HVAC cartridge in accordance with any of aspects6-8, wherein the modular HVAC cartridge further comprises a controlmodule, comprising a controller including a processor and a memoryincluding instructions executable by the processor which, when executedby the processor, cause the processor to adjust the operation of theindoor fan, the outdoor fan, and/or the compressor; and a communicationsinterface.

Aspect 10. The modular HVAC cartridge in accordance with any of aspects6-9, wherein the memory further includes instructions executable by theprocessor which, when executed by the processor, cause the processor toreceive, from the communications interface, an operational parameter ofthe modular HVAC unit and/or to transmit, to the communicationsinterface, an operational status of the HVAC unit.

Aspect 11. The modular HVAC cartridge in accordance with any of aspects6-10, further comprising a peripheral dock having a data interfacecompatible with a device selected from the group consisting of a CO₂sensor, a video camera, a smart phone, a lighting controller, roomlights, an audio playback device, and a flat panel interface.

Aspect 12. The modular HVAC cartridge in accordance with any of aspects6-11, wherein the peripheral dock includes an electrical powerconnector.

Aspect 13. The modular HVAC cartridge in accordance with any of aspects6-12, wherein the indoor coil is divided into two sections that may beselectively coupled in a parallel configuration to facilitate a heatingor cooling mode, or in a serial configuration to facilitate adehumidification mode.

Aspect 14. A modular HVAC system, comprising a modular HVAC cartridge; acontrol hub in operative communication with the modular HVAC unit; atemperature sensor in operative communication with the control hub; anactive register in operative communication with the control hub; and amobile device in operative communication with the control hub.

Aspect 15. The modular HVAC system in accordance with aspect 14, whereinthe mobile device comprises a processor and a memory includinginstructions executable by the processor which, when executed by theprocessor, cause the mobile device to transmit a temperature setpoint tothe control hub and/or to receive an operational status from the controlhub.

Aspect 16. The modular HVAC system in accordance with aspect 14 or 15,wherein the control hub comprises a processor and a memory includinginstructions executable by the processor which, when executed by theprocessor, cause the control hub to receive a temperature setpoint fromthe mobile device; receive a temperature measurement from thetemperature sensor; and transmit an operational parameter to the activeregister based on the temperature setpoint and the temperaturemeasurement.

Aspect 17. The modular HVAC system in accordance with any of aspects14-16, wherein the control hub comprises a processor and a memoryincluding instructions executable by the processor which, when executedby the processor, cause the control hub to receive a temperaturesetpoint from the mobile device; receive a temperature measurement fromthe temperature sensor; and transmit an operational parameter to themodular HVAC cartridge based on the temperature setpoint and thetemperature measurement.

Aspect 18. The modular HVAC system in accordance with any of aspects14-17, further comprising a thermostat in operative communication withthe control hub.

Aspect 19. The modular HVAC system in accordance with any of aspects14-18, wherein the control hub comprises a processor and a memoryincluding instructions executable by the processor which, when executedby the processor, cause the control hub to receive a temperaturesetpoint and/or an operational parameter from the thermostat; andtransmit an operational parameter to the modular HVAC cartridge based onthe temperature setpoint and/or the operational parameter.

Aspect 20. The modular HVAC system in accordance with any of aspects14-19, further comprising a remote server in operative communicationwith the control hub, the remote server comprising a processor; and amemory including instructions executable by the processor which, whenexecuted by the processor, cause the remote server to receive one ormore operational parameters from the control hub; store the receivedoperational parameters in a backup database; and transmit one or more ofthe stored operational parameters to the control hub.

Aspect 21. The modular HVAC system in accordance with any of aspects14-20, further comprising a remote server in operative communicationwith the control hub, the remote server comprising a processor; and samemory including instructions executable by the processor which, whenexecuted by the processor, cause the remote server to receive one ormore operational parameters from the mobile device; and transmit one ormore of the received operational parameters to the control hub.

Aspect 22. The modular HVAC system in accordance with any of aspects14-21, wherein the active register comprises a communications interface;a fan; and a controller comprising a processor, and a memory includinginstructions executable by the processor which, when executed by theprocessor, cause the active register to receive a fan command from thecontrol hub and adjust the speed of the fan in accordance with the fancommand.

Aspect 23. The modular HVAC system in accordance with any of aspects14-22, wherein the active register comprises a communications interface;a fan; and a controller comprising a processor, and a memory includinginstructions executable by the processor which, when executed by theprocessor, cause the active register to receive a setpoint temperaturefrom the control hub; receive a temperature measurement from thetemperature sensor; and adjust the fan speed in accordance with thesetpoint temperature and the temperature measurement.

Aspect 24. The modular HVAC system in accordance with any of aspects14-23, wherein the memory of the active register further includesinstructions executable by the processor which, when executed by theprocessor, cause the active register to transmit the fan speed to thecontrol hub.

What is claimed is:
 1. An in-wall enclosure for mounting a modular HVACcartridge within a space defined by an exterior sheathing of a building,a first vertical stud, and a second vertical stud, comprising: an indoorduct opening and an outdoor duct opening defined therein; an outdoor airinlet defined therein; and a front opening exposing a cavity configuredto operatively receive a modular HVAC cartridge.
 2. The in-wallenclosure in accordance with claim 1, further comprising: an indoor ductextending from the indoor duct opening to an indoor duct outlet; and anoutdoor duct extending from the outdoor duct opening to an outdoor ductoutlet.
 3. The in-wall enclosure in accordance with claim 1, furthercomprising a condensate outlet port.
 4. The in-wall enclosure inaccordance with claim 1, further comprising an electrical connectordisposed in the cavity.
 5. The in-wall enclosure in accordance withclaim 4, wherein the electrical connector is positioned to electricallyengage a mating connector provided on the modular HVAC cartridge whenthe modular HVAC cartridge is positioned in the in-wall enclosure.
 6. Amodular HVAC cartridge, comprising: a housing having at least a rearside, a top side, and a front side, the housing dimensioned to mate withthe cavity of an in-wall enclosure; an indoor air port defined in thehousing and configured to mate with the indoor duct of an in-wallenclosure; an outdoor air port defined in the housing and configured tomate with the outdoor duct of an in-wall enclosure; an indoor air inletdefined in the housing; an outdoor air inlet defined in the housing; anindoor coil disposed between the indoor air inlet and the indoor airport; an indoor fan for moving indoor air from the indoor air inlet tothe indoor air port; an outdoor coil disposed between the outdoor airinlet and the outdoor air port; an outdoor fan for moving outdoor airfrom the outdoor air inlet to the outdoor air port; and a compressor influid communication with the indoor coil and the outdoor coil forperforming a vapor-compression cycle.
 7. The modular HVAC cartridge inaccordance with claim 6, further comprising: an indoor condensate panpositioned beneath the indoor coil; and an outdoor condensate panpositioned beneath the outdoor coil.
 8. The modular HVAC cartridge inaccordance with claim 7, further comprising a drain pipe having an upperend and a lower end, wherein the upper end is in fluid communicationwith the indoor condensate pan, and wherein the lower end is in fluidcommunication with the outdoor condensate pan.
 9. The modular HVACcartridge in accordance with claim 6, further comprising a controlmodule, comprising: a controller including a processor and a memoryincluding instructions executable by the processor which, when executedby the processor, cause the processor to adjust the operation of theindoor fan, the outdoor fan, and/or the compressor; and a communicationsinterface.
 10. The modular HVAC cartridge in accordance with claim 9,wherein the memory further includes instructions executable by theprocessor which, when executed by the processor, cause the processor toreceive, from the communications interface, an operational parameter ofthe modular HVAC cartridge and/or to transmit, to the communicationsinterface, an operational status of the modular HVAC cartridge.
 11. Themodular HVAC cartridge in accordance with claim 6, further comprising aperipheral dock having a data interface compatible with a deviceselected from the group consisting of a CO₂ sensor, a video camera, asmart phone, a lighting controller, room lights, an audio playbackdevice, and a flat panel interface.
 12. The modular HVAC cartridge inaccordance with claim 11, wherein the peripheral dock includes anelectrical power connector.
 13. The modular HVAC cartridge in accordancewith claim 6, wherein the indoor coil is divided into two sections thatmay be selectively coupled in a parallel configuration to facilitate aheating or cooling mode, or in a serial configuration to facilitate adehumidification mode.
 14. A modular HVAC system, comprising: a modularHVAC unit; a control hub in operative communication with the modularHVAC unit; a temperature sensor in operative communication with thecontrol hub; an active register in operative communication with thecontrol hub; and a mobile device in operative communication with thecontrol hub.
 15. The modular HVAC system in accordance with claim 14,wherein the mobile device comprises a processor and a memory includinginstructions executable by the processor which, when executed by theprocessor, cause the mobile device to transmit a temperature setpoint tothe control hub and/or to receive an operational status from the controlhub.
 16. The modular HVAC system in accordance with claim 14, whereinthe control hub comprises a processor and a memory includinginstructions executable by the processor which, when executed by theprocessor, cause the control hub to: receive a temperature setpoint fromthe mobile device; receive a temperature measurement from thetemperature sensor; and transmit an operational parameter to the activeregister based on the temperature setpoint and the temperaturemeasurement.
 17. The modular HVAC system in accordance with claim 14,wherein the control hub comprises a processor and a memory includinginstructions executable by the processor which, when executed by theprocessor, cause the control hub to: receive a temperature setpoint fromthe mobile device; receive a temperature measurement from thetemperature sensor; and transmit an operational parameter to the modularHVAC unit based on the temperature setpoint and the temperaturemeasurement.
 18. The modular HVAC system in accordance with claim 14,further comprising a thermostat in operative communication with thecontrol hub.
 19. The modular HVAC system in accordance with claim 18,wherein the control hub comprises a processor and a memory includinginstructions executable by the processor which, when executed by theprocessor, cause the control hub to: receive a temperature setpointand/or an operational parameter from the thermostat; and transmit anoperational parameter to the modular HVAC unit based on the temperaturesetpoint and/or the operational parameter.
 20. The modular HVAC systemin accordance with claim 14, further comprising a remote server inoperative communication with the control hub, the remote servercomprising: a processor; and a memory including instructions executableby the processor which, when executed by the processor, cause the remoteserver to: receive one or more operational parameters from the controlhub; store the received operational parameters in a backup database; andtransmit one or more of the stored operational parameters to the controlhub.
 21. The modular HVAC system in accordance with claim 14, furthercomprising a remote server in operative communication with the controlhub, the remote server comprising: a processor; and a memory includinginstructions executable by the processor which, when executed by theprocessor, cause the remote server to: receive one or more operationalparameters from the mobile device; and transmit one or more of thereceived operational parameters to the control hub.
 22. The modular HVACsystem in accordance with claim 14, wherein the active registercomprises: a communications interface; a fan; and a controllercomprising a processor, and a memory including instructions executableby the processor which, when executed by the processor, cause the activeregister to: receive a fan command from the control hub; and adjust thespeed of the fan in accordance with the fan command.
 23. The modularHVAC system in accordance with claim 14, wherein the active registercomprises: a communications interface; a fan; and a controllercomprising a processor, and a memory including instructions executableby the processor which, when executed by the processor, cause the activeregister to: receive a setpoint temperature from the control hub;receive a temperature measurement from the temperature sensor; andadjust the fan speed in accordance with the setpoint temperature and thetemperature measurement.
 24. The modular HVAC system in accordance withclaim 23, wherein the memory of the active register further includesinstructions executable by the processor which, when executed by theprocessor, cause the active register to transmit the fan speed to thecontrol hub.